EP1992480A1 - A panel and a method of manufacturing a panel - Google Patents

A panel and a method of manufacturing a panel Download PDF

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Publication number
EP1992480A1
EP1992480A1 EP20070108351 EP07108351A EP1992480A1 EP 1992480 A1 EP1992480 A1 EP 1992480A1 EP 20070108351 EP20070108351 EP 20070108351 EP 07108351 A EP07108351 A EP 07108351A EP 1992480 A1 EP1992480 A1 EP 1992480A1
Authority
EP
European Patent Office
Prior art keywords
panel
pigment
top layer
side
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20070108351
Other languages
German (de)
French (fr)
Inventor
Bruno Paul Louis Vermeulen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Spanolux Div Balterio NV
Original Assignee
Spanolux Div Balterio NV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Spanolux Div Balterio NV filed Critical Spanolux Div Balterio NV
Priority to EP20070108351 priority Critical patent/EP1992480A1/en
Publication of EP1992480A1 publication Critical patent/EP1992480A1/en
Application status is Withdrawn legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0484Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper containing metallic elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F1/00Designs or pictures characterised by special or unusual light effects
    • B44F1/02Designs or pictures characterised by special or unusual light effects produced by reflected light, e.g. matt surfaces, lustrous surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F9/00Designs imitating natural patterns
    • B44F9/02Designs imitating natural patterns wood grain effects
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24851Intermediate layer is discontinuous or differential
    • Y10T428/24868Translucent outer layer
    • Y10T428/24876Intermediate layer contains particulate material [e.g., pigment, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24851Intermediate layer is discontinuous or differential
    • Y10T428/24868Translucent outer layer
    • Y10T428/24884Translucent layer comprises natural oil, wax, resin, gum, glue, gelatin
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24901Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter

Abstract

A panel (1), in particular a floor panel (1), comprises at least a decorated side (5), which is provided with a pigment (7) for creating a lustrous effect to the appearance of the decorated side (5). The decorated side (5) may comprise a decoration surface (3) and a substantially transparent protective top layer (4) covering the decoration surface (3). The top layer (4) can be provided with at least wear-resistant particles (6) having limited or non-translucent properties, wherein the pigment (7) is embedded in the top layer (4).

Description

  • The invention relates to a panel, in particular a floor panel, comprising at least a decorated side.
  • Such a panel is well-known in the state of the art. In particular, floor panels are often provided with a decorated side imitating natural materials, such as a wood pattern of genuine wood planks.
  • It is an object of the present invention to provide a panel which imitates natural materials better.
  • In order to achieve this object the decorated side is provided with a pigment for creating a lustrous effect to the appearance of the decorated side.
  • Due to this feature the panel obtains a lustrous or glittering appearance, such as can be observed with some natural materials, such as wood planks.
  • In a practical embodiment the decorated side comprises a decoration surface and a substantially transparent protective top layer covering the decoration surface, wherein the top layer is provided with at least wear-resistant particles having limited or non-translucent properties, and the pigment is embedded in the top layer.
  • Embedding the pigment in the top layer is advantageous, because if the pigment were provided below the protective top layer, the wear-resistant particles in the top layer might reduce or even eliminate the effect of the pigment. The wear-resistant particles present in the protective top layer may be aluminium oxide or corundum, for example. This type of particles typically tends to reduce the lustrous effect of the pigment if this would be provided below the protective top layer. It is noted, that the decoration surface may be formed on a decoration layer laminated onto the panel, but a decorative pattern directly printed on an upper side of the panel is also conceivable.
  • The pigment may be such a material that it provides a metallic effect to the appearance of the decorated side of the panel. This may give an optical effect comparable with that of a metallic paint of a car body.
  • It is advantageous when the pigment is a non-metallic pigment, because it minimizes the risk of oxidation, thus leading to a stable optical effect of the pigment. Such a pigment is Iriodin®, for example, commercialized by the company Merck.
  • The top layer may comprise a paper sheet impregnated with a resin, and the pigment is disposed in the resin. The resin is, for example, a melamine-based resin. This can be implemented in an existing production method rather simple. Furthermore, it provides the opportunity to distribute the pigment evenly within the resin resulting in a uniformly distributed lustrous effect. The pigment is not necessarily distributed homogeneously within the top layer, but may have a higher or lower concentration within certain areas. It is conceivable that the wear-resistant particles are also provided in the resin, which may further improve an even distribution of both the pigment and the wear-resistant particles within the resin.
  • The wear-resistant particles may be disposed in pores of the paper. This is advantageous since the pigment may be disposed between the pores which are filled with the wear-resistant particles hence avoiding disturbance of the optical effect of the pigment by the particles.
  • Alternatively, the top layer comprises a paper sheet impregnated with a resin, and the paper sheet is provided with the pigment. In this case the pigment is not added to the resin before impregnating the paper sheet.
  • A practical material the wear-resistant particles can be made of, is for example corundum. This appears to have good properties against wear.
  • The invention also relates to a method of manufacturing a panel, including the steps of: providing a panel having at least one side to be decorated; applying a decoration pattern on the side; applying a protective top layer onto the side having the decoration pattern, wherein a pigment is added to the top layer.
  • In an advantageous way the protective top layer is prepared by providing a paper sheet and impregnating the paper sheet by a resin containing the pigment, before applying the protective top layer onto the side. This is a relatively simple method to obtain the panel such as described hereinbefore.
  • The resin may also contain wear-resistant particles so as to provide the opportunity to obtain an even distribution of both the pigment and the wear-resistant particles within the top layer.
  • The invention will hereafter be elucidated with reference to the drawing showing an embodiment of the invention by way of example.
  • Fig. 1 is a very schematic cross-sectional view of an embodiment of a panel according to the invention.
  • Fig. 1 shows a cross-section of an embodiment of a panel 1 according to the invention, in this case a floor panel 1. The panel 1 comprises a core 2, a decoration layer 3 and a protective top layer or overlay 4. The core 2 may comprise one or more layers of MDF, HDF, HTSP, PVC, composites or the like, and possibly a balancing layer. It is noted that the core 2 and the layers 3, 4 such as shown in Fig. 1 have different scales in practice. The layers 3, 4 will generally be much thinner than the core 2. The decoration layer 3 is provided with a surface decoration which imitates natural materials, such as wood.
  • The decoration layer 3 includes a laminate of paper layers impregnated with a resin. It is also possible that a decoration pattern is directly applied onto the core 2, such that the decoration layer 3 is formed by a coating or paint or the like. In any case an upper surface of the decoration layer 3 forms a decoration surface of the panel.
  • The embodiment of Fig. 1 has an upper surface 5, which is seen as the decorated side of the panel 1 by an observer. The protective top layer 4 covers the decoration layer 3 and is substantially transparent. This means that the decoration layer 3 can be seen through the protective top layer 4. The protective top layer 4 is provided with wear-resistant particles 6, such as illustrated by squares in Fig. 1. These particles 6 may be made of aluminium oxide or corundum or the like, and have limited or non-translucent properties. Nevertheless, the particles 6 have such a size and are distributed within the protective top layer 4 such that the decoration layer 3 can still be observed through the protective top layer 4.
  • In the embodiment of the panel 1 a pigment 7 is embedded in the top layer 4. The pigment is illustrated by circles in Fig. 1. The pigment 7 creates a lustrous effect to the appearance of the upper side 5 of the panel 1. It may imitate a metallic-like glittering effect of real wood planks, for example. It is advantageous when the pigment 7 is a non-metallic pigment, since it minimizes the risk of oxidation thereof. In the embodiment shown in Fig. 1 the top layer 4 comprises a paper sheet 9 which is impregnated with a resin 10. The pigment 7 as well as the wear-resistant particles 6 are embedded in the resin. In practice, after impregnating the paper sheet 9 with resin 10 it is laminated onto the decoration layer 3 of the panel 1 by means of elevated pressure and temperature.
  • It appears that the lustrous effect due to the pigment 7 in the top layer 4 is improved with respect to the condition in which the pigment is disposed below the top layer 4 since the wear-resistant particles 6 may disturb the lustrous effect of the pigment 7 in this case.
  • In an alternative embodiment the wear-resistant particles are disposed in pores of the paper sheet 9 (not shown). In this case the pigment 7 is added to the resin 10 and impregnated to the paper 9 which contains the particles 7.
  • In still another alternative embodiment the top layer 4 may comprise a paper sheet 9 impregnated with a resin 10, wherein the paper sheet 9 is provided with the pigment 7 (not shown). In this case the wear-resistant particles 6 can be added to the resin 10 with which the paper sheet 9 is subsequently impregnated.
  • From the foregoing it may be clear that the panel according to the invention provides a decorated side having a lustrous effect, hence imitating natural materials better.
  • The invention is not limited to the embodiment shown in the drawing and the embodiments described hereinbefore, which may be varied in different manners within the scope of the claims and their technical equivalents. It is, for example, possible to provide the pigment below the top layer, in particular in case of applying wear-resistant particles which have good translucent properties or in case of no or a low density of wear-resistant particles. Furthermore, a paper sheet may be omitted in the top layer; a top layer formed by a coating containing wear-resistant particles and pigment is conceivable. At least a part of the decoration layer may also be provided on the top layer or overlay. Besides, the top layer may be embossed, possibly in register with a pattern on the decoration layer.

Claims (11)

  1. Panel (1), in particular a floor panel (1), comprising at least a decorated side (5), characterized in that the decorated side (5) is provided with a pigment (7) for creating a lustrous effect to the appearance of the decorated side (5).
  2. Panel (1) according to claim 1, wherein the decorated side (5) comprises a decoration surface (3) and a substantially transparent protective top layer (4) covering the decoration surface (3), said top layer (4) being provided with at least wear-resistant particles (6) having limited or non-translucent properties, wherein the pigment (7) is embedded in the top layer (4).
  3. Panel (1) according to claim 1 or 2, wherein the pigment (7) is such a material that it provides a metallic effect to the appearance of the decorated side (5) of the panel (1).
  4. Panel (1) according to one of the preceding claims, wherein the pigment (7) is a non-metallic pigment.
  5. Panel (1) according to claim 2 and one of the claims 3-4, wherein the top layer comprises a paper sheet (9) impregnated with a resin (10), and the pigment (7) is disposed in the resin (10).
  6. Panel (1) according to claim 5, wherein the wear-resistant particles (6) are disposed in pores of the paper (9).
  7. Panel (1) according to claim 2 and one of the claims 3-4, wherein the top layer (4) comprises a paper sheet (9) impregnated with a resin (10), and the paper sheet (10) is provided with the pigment (7).
  8. Panel (1) according to claim 2 and one of the claims 3-7, wherein the wear-resistant particles (6) are made of corundum.
  9. Method of manufacturing a panel (1), including the steps of:
    - providing a panel (1) having at least one side to be decorated,
    - applying a decoration pattern on the side,
    - applying a protective top layer (4) onto the side having the decoration pattern,
    characterized in that a pigment (7) is added to the top layer (4).
  10. Method according to claim 9, wherein before applying the protective top layer (4) onto the side the protective top layer (4) is prepared by providing a paper sheet (9) and impregnating the paper sheet (9) by a resin (10) containing the pigment (7).
  11. Method according to claim 10, wherein the resin (10) also contains wear-resistant particles (6).
EP20070108351 2007-05-16 2007-05-16 A panel and a method of manufacturing a panel Withdrawn EP1992480A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20070108351 EP1992480A1 (en) 2007-05-16 2007-05-16 A panel and a method of manufacturing a panel

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP20070108351 EP1992480A1 (en) 2007-05-16 2007-05-16 A panel and a method of manufacturing a panel
US12/599,842 US20100300020A1 (en) 2007-05-16 2008-05-14 Panel and a method of manufacturing a panel
EP09173196A EP2147802A1 (en) 2007-05-16 2008-05-14 A panel and a method of manufacturing a panel
PCT/EP2008/055922 WO2008138952A2 (en) 2007-05-16 2008-05-14 A panel and a method of manufacturing a panel

Publications (1)

Publication Number Publication Date
EP1992480A1 true EP1992480A1 (en) 2008-11-19

Family

ID=38328952

Family Applications (2)

Application Number Title Priority Date Filing Date
EP20070108351 Withdrawn EP1992480A1 (en) 2007-05-16 2007-05-16 A panel and a method of manufacturing a panel
EP09173196A Withdrawn EP2147802A1 (en) 2007-05-16 2008-05-14 A panel and a method of manufacturing a panel

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP09173196A Withdrawn EP2147802A1 (en) 2007-05-16 2008-05-14 A panel and a method of manufacturing a panel

Country Status (3)

Country Link
US (1) US20100300020A1 (en)
EP (2) EP1992480A1 (en)
WO (1) WO2008138952A2 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103291047A (en) * 2012-02-27 2013-09-11 上海劲嘉建材科技有限公司 Magnetic floor tiles and manufacturing method thereof

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
PL2363299T3 (en) * 2010-03-05 2013-02-28 Unilin Bvba A method of manufacturing a floor board
US10035358B2 (en) * 2012-07-17 2018-07-31 Ceraloc Innovation Ab Panels with digital embossed in register surface
US9446602B2 (en) 2012-07-26 2016-09-20 Ceraloc Innovation Ab Digital binder printing
US9738095B2 (en) 2013-01-11 2017-08-22 Ceraloc Innovation Ab Digital printing with transparent blank ink
US10041212B2 (en) * 2013-02-04 2018-08-07 Ceraloc Innovation Ab Digital overlay
EP2995741B8 (en) * 2014-09-15 2018-02-21 Wed S.R.L. Waterproof decorative sheath system for walls of moist environments, and method for making it

Citations (5)

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Publication number Priority date Publication date Assignee Title
JPS6384936A (en) * 1986-09-30 1988-04-15 Ibiden Co Ltd Decorative board with metallic gloss surface and manufacture thereof
EP0357808A1 (en) * 1988-08-29 1990-03-14 Th. Goldschmidt AG Process for applying decorative coatings to flat materials to produce a marble effect and a suitable plastic-containing carrier sheet for the purpose
EP1207051A2 (en) * 2000-11-15 2002-05-22 Armstrong World Industries, Inc. Pigmented radiation cured wear layer
US20030207083A1 (en) * 1999-12-23 2003-11-06 Krister Hansson Process for the manufacturing of surface elements
WO2005025862A1 (en) * 2003-09-12 2005-03-24 Dai Nippon Printing Co., Ltd. Pearl-like decorative paper having suitability for postforming and thermosetting resin decorative sheet

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GB674149A (en) * 1949-06-30 1952-06-18 Herbert John Mallabar Improvements in the manufacture of decorative laminae
JPS53134873A (en) * 1977-04-30 1978-11-24 Yamaka Sangiyou Kk Production of decorative plate
US4756951A (en) * 1986-06-12 1988-07-12 Mannington Mills Inc. Decorative surface coverings having platey material
DE19508797C1 (en) * 1995-03-15 1996-08-29 Graudenz & Partner Consultatio A process for the manufacture of decorative paper for use in the preparation of abrasion-resistant laminates
SE504353C2 (en) * 1995-06-19 1997-01-20 Perstorp Ab Process for the manufacture of a decorative thermosetting laminate
EP0993944A3 (en) * 1998-10-15 2001-06-13 International Paper Company High pressure laminate with three-dimensional appearance
DE19933710A1 (en) * 1999-07-19 2001-01-25 Daniele Casalini A surface-coated hard material
DE10252865A1 (en) * 2002-11-12 2004-05-27 Kronotec Ag Process for creating a structured decoration in a wood-based panel

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6384936A (en) * 1986-09-30 1988-04-15 Ibiden Co Ltd Decorative board with metallic gloss surface and manufacture thereof
EP0357808A1 (en) * 1988-08-29 1990-03-14 Th. Goldschmidt AG Process for applying decorative coatings to flat materials to produce a marble effect and a suitable plastic-containing carrier sheet for the purpose
US20030207083A1 (en) * 1999-12-23 2003-11-06 Krister Hansson Process for the manufacturing of surface elements
EP1207051A2 (en) * 2000-11-15 2002-05-22 Armstrong World Industries, Inc. Pigmented radiation cured wear layer
WO2005025862A1 (en) * 2003-09-12 2005-03-24 Dai Nippon Printing Co., Ltd. Pearl-like decorative paper having suitability for postforming and thermosetting resin decorative sheet

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103291047A (en) * 2012-02-27 2013-09-11 上海劲嘉建材科技有限公司 Magnetic floor tiles and manufacturing method thereof
CN103291047B (en) * 2012-02-27 2015-06-24 上海劲嘉建材科技有限公司 Magnetic floor tiles and manufacturing method thereof

Also Published As

Publication number Publication date
WO2008138952A2 (en) 2008-11-20
WO2008138952A3 (en) 2009-04-30
US20100300020A1 (en) 2010-12-02
EP2147802A1 (en) 2010-01-27

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